Face mount inserts

ABSTRACT

This invention relates to an insert component to be affixed to a panel. The insert component comprises a body, the body including a first face and a second face, the body defining at least one opening extending between the first face and the second face, said at least one opening positioned within a perimeter of the body. A flange portion extends substantially radially outwardly from one or each of said at least one opening. At least one rim is provided upon said first face and substantially about a perimeter of each said opening. At least one channel region is provided in said first face and substantially about the perimeter of each said opening, said channel region located outwardly of said rim relative to said perimeter of each said opening.

FIELD OF THE INVENTION

The present invention relates to a component which can be affixed to apanel or affixed into a rebate of a panel, the component providing for astructural support for an item to be located within an aperture of saidpanel, or relates to an insert for altering the shape or size of anexisting aperture through a panel, more particularly, though not solely,to a pre-form to be used as an insert into an existing aperture througha building panel.

BACKGROUND TO THE INVENTION

Various solutions have been proposed for reducing the size of anaperture through a panel, such as a ceiling or wall panel. Inparticular, problems exist where for example an existing aperture of acertain size has been made to accommodate, say a lighting fixture or aconduit to pass through the panel, but then that fixture or conduit isto be replaced with a smaller size which no longer needs the existingaperture size.

Indeed, where the aperture size for the replacement fixture or conduitor any other such device extending through an aperture is smaller thanthe existing aperture, there becomes a problem as to how to adequatelyreduce the aperture whilst also ameliorating the gap between theexisting aperture side wall and the size of the device to extendingthrough the panel.

Typically, an existing aperture may be in-filled by using a piece orpieces of the same (or different) panel material. However, the jointedregion between such in-fill materials and the panel itself may be weakor may weaken or fail over time. For example, where there is an existingcircular aperture through a ceiling panel and that existing aperture isto be reduced in size, an annular ring of material may be cut to beinserted into the existing aperture to provide the new aperture size.The joint between the outer surface of the annular ring and the panelmay be connected to each other using joint tapes and layers ofconcealing material (e.g. plaster). However, such a solution stillpresents problems as the joint region may fail or weaken, leading toproblems of cracked concealing material (plaster) or other finishingmaterials (e.g. paints).

In this specification where reference has been made to patentspecifications, other external documents, or other sources ofinformation, this is generally for the purpose of providing a contextfor discussing the features of the invention. Unless specifically statedotherwise, reference to such external documents is not to be construedas an admission that such documents, or such sources of information, inany jurisdiction, are prior art, or form part of the common generalknowledge in the art.

Further aspects and advantages of the present invention will becomeapparent from the ensuing description which is given by way of exampleonly.

SUMMARY OF THE INVENTION

It may therefore be an object of the present invention to provide for aninsert component to be affixed to a panel to provide for a supportstructure about an aperture through said panel and/or which will go atleast some way towards addressing the foregoing problems or which willat least provide the public with a useful choice. Such an insert isconfigured to receive or locate an item, such as a light fitting orfixture, or another item as may be described in this specification. Itwill be appreciated other items may be supported by the insert componentas disclosed in this specification and need not be limited to thoseitems which are specifically disclosed herein.

It may also be an object of the present invention to provide for aninsert component capable of altering the shape and/or size of anexisting aperture through a panel and/or which will go at least some waytowards addressing the foregoing problems or which will at least providethe public with a useful choice.

In a first aspect there is provided an insert component to be affixed toa panel, said insert component comprising:

a body, the body including a first face and a second face, the bodydefining at least one opening extending between the first face and thesecond face, said at least one opening positioned within a perimeter ofthe body,

a flange portion extending substantially radially outwardly from one oreach of said at least one opening, and

at least one first rim provided upon said first face and substantiallyabout a perimeter of each said opening, and at least one second rimprovided upon said first face and substantially about the perimeter ofeach said opening, wherein said first rim is located outwardly of saidsecond rim relative to said perimeter of each said opening,

and wherein each of said first rim and said second rim are spaced fromeach other to define a channel region.

Each of said first rim and said second rim may be projections extendingupwardly or away from said first face.

Each of said first rim and said second rim may be provided asprojections upstanding from said first face.

The first rim may be of a first rim height relative to a first facesurface of said flange portion, and said second rim may be of a secondrim height relative to a first face surface of said flange portion.

The first rim height may be substantially equal to or less than saidsecond rim height.

The second rim height may be substantially equal to or greater than saidfirst rim height.

The first rim height may be less than said second rim height.

A height of the first rim may be about 1 mm, or about 2 mm, or about 3mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, orless than about 8 mm, or less than about 6 mm, or less than about 4 mm,or less than about 2 mm, as measured from said first face of said body.

A height of the second rim may be about 2 mm, or about 3 mm, or about 4mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be lessthan about 12 mm, or less than about 10 mm, or less than about 8 mm, orless than about 6 mm, or less than about 4 mm, or less than about 2 mm,as measured from said first face of said body.

The channel region may have a floor or base defining a channel regiondepth, said floor or base being of a level, or providing for floor orbase sections of a level, which may be one or more of:

-   -   a level substantially equal to said first surface of said flange        portion,    -   a level substantially lower than said first surface of said        flange portion,    -   a level substantially higher than said first surface of said        flange portion.

The channel may be of a pre-determined width, said width defined betweenfacing side walls of each of said first rim and said second rim.

Said width may be sufficient to accommodate or receive a (curable)material.

The channel may be of a width that is greater than about 1 mm, orgreater than about 2 mm, or greater than about 3 mm, or greater thanabout 4 mm, or greater than about 5 mm, or greater than about 10 mm, orgreater than about 15 mm, or may be about 2 mm, or may be about 3 mm, ormay be about 4 mm, or may be about 5 mm, or may be about 6 mm, or may beabout 8 mm, or may be about 10 mm, or may be less than 10 mm.

The material may be a filler material (such as, but not limited to, oneor more of: a plaster-type or render-type material, such as a materialcomprising of gypsum, lime or cement material, or is a material capableof being decorated or may be a material which can be finished, e.g. canbe sanded to a finished surface, for a subsequent application of adecorative material, such as paint).

One or more of said at least one opening may further comprises of aledge, said ledge providing a support surface extending substantiallyinwardly toward a centre of said opening.

The support surface may be a surface facing the same direction as saidfirst face of said body.

The support surface may be a substantially planar surface.

The support surface may provide a surface upon which an item isseatable.

The item may be a light fixture or fitting, or may be a smoke alarm orsmoke detector or other fittings or fixtures.

One or more projections may be provided upon said second face of saidbody.

The projections upon said second face of said body may extend apre-determined height or distance away from said second face.

The projections upon said second face may be provided to, in-use, spacesaid body, via said second face, away from a surface upon which saidsecond face is to be located.

The projections upon said second face may be provided to, in-use,provide a gap or a space between said second face and a surface uponwhich said second face is to be located.

The space or gap may provide a void into which a (optionally curable)material can be in-filled.

The one or more projections may be provided upon said second face ofsaid body are distributed about said second face.

The one or more projections may be provided upon said second face ofsaid body are distributed substantially evenly or equidistantly fromeach other and about said second face.

There may be six projections provided upon said second face of saidbody.

The projections upon the second face may be of a pre-determined heightor extend a distance away from the second face of about 0.5 mm, or about1 mm, or may be less than about 5 mm, or less than about 4 mm, or lessthan about 3 mm, or less than about 2 mm, or less than about 1 mm, orless than about 0.5 mm.

The flange may extend substantially about a part, or parts, orsubstantially an entirety, of said perimeter of said body.

The flange may extend as two opposing sides of said body (i.e. there arecut-off or straight side portions).

The flange may comprise one or more apertures, said apertures extendingthrough said body.

The apertures may provide for a void through said body.

The apertures may be distributed about said flange.

The second face of said body may be a substantially planar surface.

The second face of said body may be substantially planar, apart from oneor more projections provided upon said second face of said body.

The body may be substantially circular, oval or of a rectilinearperimeter shape.

One or more of said at least one opening(s) may be substantiallycircular, oval or of a rectilinear perimeter shape.

The ledge may be substantially circular, oval or of a rectilinearperimeter shape.

A diameter of an inner perimeter of said second rim may be about 25 mmto about 104 mm, or may be about 76 mm, or may be about 86 mm, or about102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106mm, or may be about 160 mm, or may be about 200 mm, or may be greaterthan about 10 mm, or greater than about 20 mm, or greater than about 25mm, or greater than about 30 mm, or greater than about 35 mm, or greaterthan about 40 mm, or greater than about 50 mm, or greater than about 85mm, or greater than about 100 mm, or greater than about 105 mm, orgreater than about 125 mm, or greater than about 150 mm, or greater thanabout 175 mm, or greater than about 200 mm, or greater than about 300mm, or greater than about 400 mm.

The flange may be detachable or attachable or integral with said body.

The first rim or said second rim, or both, may be detachable orattachable or with said body.

The ledge may be detachable or attachable or integral with said body.

The projections provided upon said second face of said body maydetachable or attachable or integral with said body.

A separate component piece, such as a plate-type component piece, may beprovided for seating upon the ledge.

The separate component piece may be provided as a plate-type componentpiece comprising of one or more apertures.

The separate component piece may be provided as a plug or cap for theinsert component.

The separate component piece is substantially planar and of asubstantially constant thickness.

The thickness of the separate component piece may be sufficient so as toalign or be substantially matched with the second rim

The second rim may be of about a 2 mm height, the first rim may be ofabout a 1 mm height.

The separate component piece may be of about a 2 mm thickness.

In a second aspect there is provided a structure formed in-situ with apanel, wherein an insert as defined in the first aspect or according toany preceding statement is affixed to a face of a panel.

A rebate is formed in said face of said panel, said rebate being of adepth to receive said insert, such that an end of said second rim issubstantially level or aligned with said face of said panel, or anintended level of a finished or decorated surface of said panel.

It is further contemplated that where a light fitting or fixture isdescribed, said light fitting may be substituted with any other fittingor component to be installed into a panel, such as, speakers, furniture,ducts, piping, components of alarm or safety systems (e.g., smokedetectors, gas detectors, infrared motion detectors) or any otheroutlet, utility or appliance.

It is further contemplated that any such fittings or components orsystems to be installed may be retrofitted with suitable adaptors forinstalling into a body or assembly as described in any one of thepreceding aspects or embodiments.

It is further contemplated that an assembly may comprise the body asdescribed herein, and in particular with reference to any one or more ofthe preceding aspects or embodiments.

The invention described herein provides for at least two separate rims,being of the same or different height projections of the first face ofthe body, where at least the first rim provides for a first referenceheight and the second rim provides for a second reference height. Thereference heights being made with reference to the first face of thebody or with reference to a face of a panel into which the insert is tobe affixed or received.

In certain embodiments, the first rim is of a lower or smaller height orsize then the second rim. In this manner, where for example a (curable)material such as a plaster is to be applied over the insert (for exampleto affixed of mechanically engage the insert with the panel to which itis to be affixed), a first application of a material can be made uponthe insert, and an amount of material can be applied such that thematerial is applied to a thickness to align with the first rim. A secondor subsequent layer of material may then be applied or coated, and thismay be to a thickness to align with the second rim.

It will be appreciated the body of this invention may also be utilisedfor use in altering or reducing or amending the shape or dimension ofother aspects of an aperture or opening through a panel.

In a third aspect there is provided an insert component to be affixed toa panel, said insert component comprising:

a body, the body including a first face and a second face, the bodydefining at least one opening extending between the first face and thesecond face, said at least one opening positioned within a perimeter ofthe body,

a flange portion extending substantially radially outwardly from one oreach of said at least one opening, and

wherein at least a portion at the perimeter of the body is adjustableand/or adaptable toward and/or away from the at least one opening.

The perimeter is moveable, preferably radially, so as to provide abiasing means for retaining the body in a rebate formed in the face of apanel, the rebate being of a depth to receive said insert.

In a particular form the rebate is formed in a ceiling structure and theat least one opening is adapted to receive a lighting fixture or thelike ceiling fixture such as a sensor. In a preferred form the rebate issized so as to receive the insert with minimal clearance such that theadjustable perimeter is adjustable/adaptable to engage a side of therebate.

A suitable retention means for adjusting the perimeter may be by way ofat least one resilient element located at the perimeter of the body,adapted to provide an outward bias to retain the body of the insert in arebate. When in a retained state a user can apply a (curable) materialsuch as a plaster over the insert. The retention means can alternativelybe termed a biasing element, perimeter expander, spring-biased member orany combination of these terms.

The resilient element may include an outward projection beyond the mainperimeter. The projection may be of bevelled/tapered or spike form toengage into a surface of the rebate, in use.

The insert of the third aspect may incorporate and be combined with anyor all additional features described above in relation to the first orsecond aspect of the invention. For example, the insert of the inventionmay further include projections or bumps on the rebate-facing face ofthe body so as to provide a spacing function of the body from the rebateinner surface and allow flow of adhesive and/or curable material such asplaster. In a fourth aspect there is provided an insert component to beaffixed to a panel, said insert component comprising:

a body, the body including a first face and a second face, the bodydefining at least one opening extending between the first face and thesecond face, said at least one opening positioned within a perimeter ofthe body,

a flange portion located substantially radially outwardly from one oreach of said at least one opening,

at least one rim provided upon said first face and substantially about aperimeter of each said opening, and

wherein said flange portion has a relatively greater wall thickness in aregion adjacent to or at said rim, and is of a relatively reduced wallthickness in a region adjacent to or at said perimeter of said body.

At least one channel region may be provided in said first face andsubstantially about the perimeter of each said opening, said channelregion located outwardly of said rim relative to said perimeter of eachsaid opening.

The rim may be a projection extending upwardly or in a direction awayfrom said first face and said second face.

The rim may be provided as a projection upstanding from said first face.

The channel may be provided as a recess in said first face.

The channel may be located between the rim and said flange portion.

The rim may form a first channel wall of said channel.

A height of said first channel wall may be substantially equal to orgreater than a second channel wall, and the second channel wall may belocated outwardly of said first channel wall relative to said perimeterof each said opening.

A height of the rim may be about 2 mm, or about 3 mm, or about 4 mm, orabout 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm,or about 10 mm, or about 11 mm, or about 12 mm, or may be less thanabout 12 mm, or less than about 10 mm, or less than about 8 mm, or lessthan about 6 mm, or less than about 4 mm, or less than about 2 mm, asmeasured from said first face of said body.

The channel region may have a floor or base defining a channel regiondepth, said floor or base being of a level, or providing for floor orbase sections of a level substantially lower than said first face ofsaid body and/or said flange portion.

A depth of the channel may be about 1 mm, or about 2 mm, or about 3 mm,or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, orless than about 8 mm, or less than about 6 mm, or less than about 4 mm,or less than about 2 mm, as measured from said first face of said body.

The channel may be of a pre-determined width, said width defined betweensaid first channel wall and said second channel wall.

The width and/or said depth of said channel may be sufficient toaccommodate or receive a (curable) material.

The width of the channel may be greater than about 1 mm, or greater thanabout 2 mm, or greater than about 3 mm, or greater than about 4 mm, orgreater than about 5 mm, or greater than about 10 mm, or greater thanabout 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or isabout 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or isless than 10 mm.

The material may be a filler material (such as, but not limited to, oneor more of: a plaster-type or render-type material, such as a materialcomprising of gypsum, lime or cement material, or is a material capableof being decorated or may be a material which can be finished, e.g. canbe sanded to a finished surface, for a subsequent application of adecorative material, such as paint).

One or more of said at least one opening may further comprise of aledge, said ledge providing a support surface extending substantiallyinwardly toward a centre of said opening.

The support surface may be a surface facing the same direction as saidfirst face of said body.

The support surface may be a substantially planar surface.

The support surface may comprise a channel or recess.

The support surface of said ledge may be recessed from said rim, or maybe of a reduced height relative to said rim.

The support surface may provide a surface upon which an item isseatable.

The item may be one of: a light fixture or fitting, a smoke or firealarm or detector, a sprinkler, an audio speaker, a ceiling mountedsensor, or other fittings or fixtures or devices.

The second face may comprise an inner portion and an outer portion.

The outer portion may substantially correspond with said flange portion,and the inner portion may substantially correspond with said channel andsaid rim.

The inner portion may be a raised or stepped region, raised or steppedin a direction to accommodate said channel.

A sidewall may define a step between said outer portion and said innerportion, and may be provided as a guide for locating said body into anaperture of a panel.

The outer portion may be substantially planar.

The outer portion comprises of an adhesive, projection or fastener, andmay be adhered or affixed to a surface of a panel in use.

The outer portion may comprise one or more projections, the one or moreprojections being of a bevelled, tapered and/or of a spiked form.

The one or more projections may extend in a direction away from saidsecond face, or in a direction toward a surface of a panel to which saidinsert is to be affixed.

The one or more projections may provide for a mechanical engagement orattachment with the panel.

The one or more projections may be provided as an array about the secondface of said outer portion.

The flange portion may have a relatively greater wall thickness in theregion adjacent to or at said channel, and may be of a relativelyreduced wall thickness in a region adjacent to or at said perimeter ofsaid body.

The flange portion may be of a wall thickness of about 0.5 mm in aregion adjacent to or at said perimeter of said body.

The flange portion may be of a wall thickness of about 1 mm in a regionadjacent to or at said channel.

The flange portion may be substantially tapered in a reducing wallthickness, said wall thickness reducing in a direction as said flangeportion extends substantially radially outwardly from said channel.

The first face may comprise said rim defining a first projected height,said flange portion at or substantially adjacent to said channeldefining a second projected height, and said flange portion at orsubstantially adjacent to said perimeter defining a third projectedheight.

The rim may define a first projected height of said first face, saidflange portion at or substantially adjacent to said channel may define asecond projected height of said first face, and said flange portion ator substantially adjacent to said perimeter may define a third projectedheight of said first face.

The third projected height may be less than said second projectedheight.

The third projected height may be less than said first projected height.

The second projected height may be less than said first projectedheight.

The third projected height may be less than said second projectedheight, and said second projected height may be less than said firstprojected height.

The flange portion may slope from said first projected height to saidthird projected height.

An outer edge of said flange portion may define said perimeter of saidbody.

The first face of said outer edge may comprise a chamfered edge portion.

The first face may further comprise said support surface of said ledgedefining a fourth projected height.

The fourth projected height may be less than said first projectedheight, or matches the height of the first projected height.

The flange portion may extend substantially radially outwardly of saidchannel.

The flange portion may extend substantially about a part, or parts, orsubstantially an entirety, of said perimeter of said body.

The flange portion may extend as two opposing sides of said body (i.e.is cut-off sides), or wherein two opposing sides of said flange portionare substantially parallel.

The flange portion may comprise one or more apertures, said aperturesextending through said body.

The apertures may provide for a void through said body.

The apertures may be distributed about said flange portion.

The channel may comprise one or more channel apertures, and saidapertures may extend through said body.

The channel apertures may provide for a void through said body.

The channel apertures may be distributed about said channel.

The channel may comprise one or more ribs.

The one or more ribs may extend across said channel.

The one or more ribs may be strengthening members.

The one or more ribs may provide for a strengthening structure between awall of said rim and a wall of said flange portion.

The one or more ribs may extend substantially across said channel orsaid floor of said channel, or between sidewalls of said channel.

The one or more ribs may be distributed about said channel.

The one or more ribs may be of a height below the first face, or saidone or more ribs may be provided of a height recessed from said firstface, or of said flange portion.

The body may be substantially circular, oval or of a rectilinearperimeter shape.

One or more of said at least one opening(s) may be substantiallycircular, oval or of a rectilinear perimeter shape.

The ledge may be substantially circular, oval or of a rectilinearperimeter shape.

A diameter of an inner perimeter of said rim may be about 25 mm to about104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about160 mm, or may be about 200 mm, or is greater than about 10 mm, orgreater than about 20 mm, or greater than about 25 mm, or greater thanabout 30 mm, or greater than about 35 mm, or greater than about 40 mm,or greater than about 50 mm, or greater than about 85 mm, or greaterthan about 100 mm, or greater than about 105 mm, or greater than about125 mm, or greater than about 150 mm, or greater than about 175 mm, orgreater than about 200 mm, or greater than about 300 mm, or greater thanabout 400 mm.

The flange may be detachable or attachable or integral with said body.

The rim or the channel, or both, may be detachable or attachable orintegral with said body.

The ledge may be detachable or attachable or integral with said body.

A separate component piece, such as a plate-type component piece, may beprovided for seating upon the ledge.

The separate component piece may be provided as a plate-type componentpiece comprising of one or more apertures.

The separate component piece may be provided as a plug or cap for theinsert component.

The separate component piece may be substantially planar and of asubstantially constant thickness.

The insert as defined in any of the first, second, third, fourth, orfifth aspects may be affixed to a face of a panel.

A rebate may be formed in said face of said panel, said rebate being ofa depth to receive said insert, such that an end of said rim issubstantially level or aligned with said face of said panel, or anintended level of a finished or decorated surface of said panel.

A structure may be formed in-situ with a panel, and said insert asdefined in any of the first, second, third, fourth, or fifth aspects maybe affixed to a face of the panel, and a rebate may be formed in saidface of said panel and sized so as to receive the insert such that theat least a portion at the perimeter of the body is configured to extendto engage a side of the rebate and retain the insert therewithin therebate.

The insert of the fourth aspect may incorporate and be combined with anyor all additional features described above in relation to the first orsecond or third aspect, or with any or all additional features describedbelow in relation to the fifth aspect of the invention. For example, theinsert of the invention may further include projections or bumps on therebate-facing face of the body so as to provide a spacing function ofthe body from the rebate inner surface and allow flow of adhesive and/orcurable material such as plaster. Additionally, the insert may compriseone or more resilient elements.

In a fifth aspect there is provided an insert component to be affixed toa panel, said insert component comprising:

a body, the body including a first face and a second face, the bodydefining at least one opening extending between the first face and thesecond face, said at least one opening positioned within a perimeter ofthe body,

a flange portion located substantially radially outwardly from one oreach of said at least one opening,

at least one rim provided upon said first face and substantially about aperimeter of each said opening, and

at least one channel region provided in said first face andsubstantially about the perimeter of each said opening, said channelregion located outwardly of said rim relative to said perimeter of eachsaid opening.

The rim may be a projection extending upwardly or in a direction awayfrom said first face and said second face.

The rim may be provided as a projection upstanding from said first face.

The channel may be provided as a recess in said first face.

The channel may be located between the rim and said flange portion.

The rim may form a first channel wall of said channel.

A height of said first channel wall may be substantially equal to orgreater than a second channel wall, and the second channel wall may belocated outwardly of said first channel wall relative to said perimeterof each said opening.

A height of the rim may be about 2 mm, or about 3 mm, or about 4 mm, orabout 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm,or about 10 mm, or about 11 mm, or about 12 mm, or may be less thanabout 12 mm, or less than about 10 mm, or less than about 8 mm, or lessthan about 6 mm, or less than about 4 mm, or less than about 2 mm, asmeasured from said first face of said body.

The channel region may have a floor or base defining a channel regiondepth, said floor or base being of a level, or providing for floor orbase sections of a level substantially lower than said first face ofsaid body and/or said flange portion.

A depth of the channel may be about 1 mm, or about 2 mm, or about 3 mm,or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, orless than about 8 mm, or less than about 6 mm, or less than about 4 mm,or less than about 2mm, as measured from said first face of said body.

The channel may be of a pre-determined width, said width defined betweensaid first channel wall and said second channel wall.

The width and/or said depth of said channel may be sufficient toaccommodate or receive a (curable) material.

The width of the channel may be greater than about 1 mm, or greater thanabout 2 mm, or greater than about 3 mm, or greater than about 4 mm, orgreater than about 5 mm, or greater than about 10 mm, or greater thanabout 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or isabout 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or isless than 10 mm.

The material may be a filler material (such as, but not limited to, oneor more of: a plaster-type or render-type material, such as a materialcomprising of gypsum, lime or cement material, or is a material capableof being decorated or may be a material which can be finished, e.g. canbe sanded to a finished surface, for a subsequent application of adecorative material, such as paint).

One or more of said at least one opening may further comprise of aledge, said ledge providing a support surface extending substantiallyinwardly toward a centre of said opening.

The support surface may be a surface facing the same direction as saidfirst face of said body.

The support surface may be a substantially planar surface.

The support surface may comprise a channel or recess.

The support surface of said ledge may be recessed from said rim, or maybe of a reduced height relative to said rim.

The support surface may provide a surface upon which an item isseatable.

The item may be one of: a light fixture or fitting, a smoke or firealarm or detector, a sprinkler, an audio speaker, a ceiling mountedsensor, or other fittings or fixtures or devices.

The second face may comprise an inner portion and an outer portion.

The outer portion may substantially correspond with said flange portion,and the inner portion may substantially correspond with said channel andsaid rim.

The inner portion may be a raised or stepped region, raised or steppedin a direction to accommodate said channel.

A sidewall may define a step between said outer portion and said innerportion, and may be provided as a guide for locating said body into anaperture of a panel.

The outer portion may be substantially planar.

The outer portion comprises of an adhesive, projection or fastener, andmay be adhered or affixed to a surface of a panel in use.

The outer portion may comprise one or more projections, the one or moreprojections being of a bevelled, tapered and/or of a spiked form.

The one or more projections may extend in a direction away from saidsecond face, or in a direction toward a surface of a panel to which saidinsert is to be affixed.

The one or more projections may provide for a mechanical engagement orattachment with the panel.

The one or more projections may be provided as an array about the secondface of said outer portion.

The flange portion may have a relatively greater wall thickness in theregion adjacent to or at said channel, and may be of a relativelyreduced wall thickness in a region adjacent to or at said perimeter ofsaid body.

The flange portion may be of a wall thickness of about 0.5 mm in aregion adjacent to or at said perimeter of said body.

The flange portion may be of a wall thickness of about 1 mm in a regionadjacent to or at said channel.

The flange portion may be substantially tapered in a reducing wallthickness, said wall thickness reducing in a direction as said flangeportion extends substantially radially outwardly from said channel.

The first face may comprise said rim defining a first projected height,said flange portion at or substantially adjacent to said channeldefining a second projected height, and said flange portion at orsubstantially adjacent to said perimeter defining a third projectedheight.

The rim may define a first projected height of said first face, saidflange portion at or substantially adjacent to said channel may define asecond projected height of said first face, and said flange portion ator substantially adjacent to said perimeter may define a third projectedheight of said first face.

The third projected height may be less than said second projectedheight.

The third projected height may be less than said first projected height.

The second projected height may be less than said first projectedheight.

The third projected height may be less than said second projectedheight, and said second projected height may be less than said firstprojected height.

The flange portion may slope from said first projected height to saidthird projected height.

An outer edge of said flange portion may define said perimeter of saidbody.

The first face of said outer edge may comprise a chamfered edge portion.

The first face may further comprise said support surface of said ledgedefining a fourth projected height.

The fourth projected height may be less than said first projectedheight, or matches the height of the first projected height.

The flange portion may extend substantially radially outwardly of saidchannel.

The flange portion may extend substantially about a part, or parts, orsubstantially an entirety, of said perimeter of said body.

The flange portion may extend as two opposing sides of said body (i.e.is cut-off sides), or wherein two opposing sides of said flange portionare substantially parallel.

The flange portion may comprise one or more apertures, said aperturesextending through said body.

The apertures may provide for a void through said body.

The apertures may be distributed about said flange portion.

The channel may comprise one or more channel apertures, and saidapertures may extend through said body.

The channel apertures may provide for a void through said body.

The channel apertures may be distributed about said channel.

The channel may comprise one or more ribs.

The one or more ribs may extend across said channel.

The one or more ribs may be strengthening members.

The one or more ribs may provide for a strengthening structure between awall of said rim and a wall of said flange portion.

The one or more ribs may extend substantially across said channel orsaid floor of said channel, or between sidewalls of said channel.

The one or more ribs may be distributed about said channel.

The one or more ribs may be of a height below the first face, or saidone or more ribs may be provided of a height recessed from said firstface, or of said flange portion.

The body may be substantially circular, oval or of a rectilinearperimeter shape.

One or more of said at least one opening(s) may be substantiallycircular, oval or of a rectilinear perimeter shape.

The ledge may be substantially circular, oval or of a rectilinearperimeter shape.

A diameter of an inner perimeter of said rim may be about 25 mm to about104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, or about 103mm, or about 104 mm, or about 105 mm, or about 106 mm, or may be about160 mm, or may be about 200 mm, or is greater than about 10 mm, orgreater than about 20 mm, or greater than about 25 mm, or greater thanabout 30 mm, or greater than about 35 mm, or greater than about 40 mm,or greater than about 50 mm, or greater than about 85 mm, or greaterthan about 100 mm, or greater than about 105 mm, or greater than about125 mm, or greater than about 150 mm, or greater than about 175 mm, orgreater than about 200 mm, or greater than about 300 mm, or greater thanabout 400 mm.

The flange may be detachable or attachable or integral with said body.

The rim or the channel, or both, may be detachable or attachable orintegral with said body.

The ledge may be detachable or attachable or integral with said body.

A separate component piece, such as a plate-type component piece, may beprovided for seating upon the ledge.

The separate component piece may be provided as a plate-type componentpiece comprising of one or more apertures.

The separate component piece may be provided as a plug or cap for theinsert component.

The separate component piece may be substantially planar and of asubstantially constant thickness.

The insert as defined in any of the first, second, third, fourth, orfifth aspects may be affixed to a face of a panel.

A rebate may be formed in said face of said panel, said rebate being ofa depth to receive said insert, such that an end of said rim issubstantially level or aligned with said face of said panel, or anintended level of a finished or decorated surface of said panel.

A structure may be formed in-situ with a panel, and said insert asdefined in any of the first, second, third, fourth, or fifth aspects maybe affixed to a face of the panel, and a rebate may be formed in saidface of said panel and sized so as to receive the insert such that theat least a portion at the perimeter of the body is configured to extendto engage a side of the rebate and retain the insert therewithin therebate.

The insert of the fifth aspect may incorporate and be combined with anyor all additional features described above in relation to the first orsecond or third or fourth aspect of the invention. For example, theinsert of the invention may further include projections or bumps on therebate-facing face of the body so as to provide a spacing function ofthe body from the rebate inner surface and allow flow of adhesive and/orcurable material such as plaster. Additionally, the insert may compriseone or more resilient elements.

The term “comprising” as used in this specification means “consisting atleast in part of”. When interpreting each statement in thisspecification that includes the term “comprising”, features other thanthat or those prefaced by the term may also be present. Related termssuch as “comprise” and “comprises” are to be interpreted in the samemanner.

This invention may also be said broadly to consist in the parts,elements and features referred to or indicated in the specification ofthe application, individually or collectively, and any or allcombinations of any two or more said parts, elements or features, andwhere specific integers are mentioned herein which have knownequivalents in the art to which this invention relates, such knownequivalents are deemed to be incorporated herein as if individually setforth.

The invention consists in the foregoing and also envisages constructionsof which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way ofexample only and with reference to the drawings, in which:

FIG. 1 illustrates a top perspective view of one embodiment of an insertcomponent,

FIG. 2 illustrates a bottom perspective view of one embodiment of aninsert component,

FIG. 3 illustrates a side or elevation view of one embodiment of aninsert component,

FIG. 4 illustrates a top or plan view of one embodiment of an insertcomponent,

FIG. 5 illustrates a bottom view of one embodiment of an insertcomponent,

FIG. 6 illustrates a cross-sectional view (section AA as shown in FIG.5) through an embodiment of an insert component,

FIG. 7 illustrates a section of an insert component according to thepresent invention illustrating how the insert component can be locatedinto a rebate of a panel, and different layers of materials applied toaffix the insert component into place,

FIG. 8 illustrates a separate component piece which may be provided forseating upon a ledge of an insert component, to provide for a plug-typearrangement,

FIG. 9 illustrates how a separate component piece of, for example thatof

FIG. 8, may be received by an insert component,

FIG. 10 illustrates a top perspective view of a second embodiment of aninsert component,

FIG. 11 illustrates a bottom perspective view of the second embodimentof insert component,

FIG. 12 illustrates a side or elevation view of the second embodiment ofinsert component, and

FIG. 13 illustrates a section of an insert component according to thesecond embodiment illustrating how the insert component can be locatedinto a rebate of a panel, and different layers of materials applied toaffix the insert component into place,

FIG. 14 illustrates a bottom perspective view of a third embodiment ofan insert component,

FIG. 15 illustrates a top perspective view of the third embodiment of aninsert component,

FIG. 16 illustrates a side or elevation view of the third embodiment ofan insert component,

FIG. 17 illustrates a bottom view of the third embodiment of an insertcomponent,

FIG. 18 illustrates a top view of the third embodiment of an insertcomponent,

FIG. 19 illustrates a cross-sectional view (section BB as shown in FIG.17) through an insert component according to the third embodiment,

FIG. 20 illustrates a section of an insert component according to thethird embodiment illustrating how the insert component can be locatedinto a rebate of a panel, and different layers of materials applied toaffix the insert component into place,

FIG. 21 illustrates a section of an insert component according to athird embodiment illustrating differences in height of an insertcomponent first face due to a rim and a taper of a flange section,

FIG. 22 illustrates a bottom view of the third embodiment of an insertcomponent including projections on a flange portion, and

FIG. 23 illustrates a side or elevation view of the third embodiment ofan insert component including projections on a flange portion.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

This invention provides for an insert component 1, that can provide fora member in the form of a body 2, to which a fitting or fixture may bemounted or seated upon and supported. Such a member can provide for aparticular structural support for a fitting or fixture to be supportedthereon or thereto.

The insert component 1 can also provide for a particular orpre-determined (i.e. a pre-formed) dimensioned or shaped opening. Suchan opening providing for receipt of a fitting or fixture. Such aparticularly dimensioned or shaped opening provided by the insertcomponent may facilitate the re-sizing or alteration in shape of anexisting aperture in a panel, the insert component capable of receivingsuch a fitting of fixture.

The insert component (as described herein) can be located or positionedinto a rebate or recessed region of a panel, such that the insertcomponent can be subsequently mechanically fixed into place, for exampleby application of one or more layers of material, such as a curablematerial like plaster or other curable medium or adhesives. In thismanner, the insert component can be integrated into the panel. Theinsert component then provides a particular structure for assisting withsuch an integration and as a support for a fixture of fitting.

This invention also provides for a relatively uncomplicated system forreducing the geometry, such as shape or size of an existing aperture,whilst as the same time provides a platform upon which materials, suchas concealing compositions—e.g. plaster, paint or other fillers orfinishes, may be applied to conceal the joint region between the insertcomponent and the surrounding panel.

It will also be appreciated the present invention may be utilised forimproving or strengthening the aperture or opening cut or made in abuilding panel to receive a fitting, such as a light fitting (or anyother outlet or utility requiring an aperture through a building panel)or a wall socket (such as for electrical outlets or indeed any otheroutlet requiring an aperture through a building panel). For example, theexisting aperture or opening referred to here may be the aperture whichis initially cut or made in a building panel to then receive a fittingor fixture.

The insert component of the invention facilitates an improvement in thestrength of the building panel around an aperture or opening through thepanel and any finishes made about the aperture so cut or made, and inthis way can help to minimise possible “break-out” in which thematerials used around the aperture or opening are compromised as totheir structural integrity due to forces imposed upon them, for exampleby a light fitting imparting a force on a building panel about theaperture. “Break out” may result in cracking of plaster or paint orother unsightly effects in decorative finishes around the aperture.

The insert component can facilitate the alteration in the shape or sizeof an aperture or opening through a panel, for example a building panelsuch as a ceiling or a wall. The following description is provided asexemplary of the invention, and is made with reference to theaccompanying drawings.

Accordingly, described below are particular details of one embodiment ofan insert component.

In one embodiment there is provided an insert component 1 to be affixedto, for example, a panel (P, see FIG. 7). The insert component 1comprises a body 2. The body 2 includes a first face 3 and a second face4. The body 1 defines at least one opening 5 that extends between thefirst face 3 and the second face 4. The at least one opening 5 ispositioned within a perimeter (such as an outer perimeter) of the body1. A flange portion 6 extending substantially radially outwardly fromone or each of said at least one opening 5. At least one first rim 7 isprovided upon the first face 3 and substantially about a perimeter ofeach opening 5. At least one second rim 8 is provided upon the firstface 3 and substantially about the perimeter of each opening 5. Thefirst rim 7 is located outwardly of the second rim 8, relative to theperimeter of each opening 5. Each of the first rim 7 and the second rim8 are spaced from each other to define a channel region 9 therebetween.

While a single opening 5 is shown in the accompanying figures, it willbe appreciated that the body 2 may be of any shape or size and couldaccommodate any number of openings, where one or more of those openingscan each be provided with the first rim and the second rim with thechannel region located between those rims. In this manner, the number ofopenings 5 in a body 2 may be customised according to the number offittings or fixtures which are to be received by the insert component 1.

As is for example shown in the figures, each of the first rim 7 andsecond rim 8 may be of the form of projections which extend in adirection upwardly or away from said first face 3 of the body 1. Thatis, the first and second rims are provided as projections upstandingfrom the first face 3.

The first rim 7 can be of a first rim height 7H relative to the firstface 3 surface of said flange portion 6, while the second rim 8 can beof a second rim height 8H relative to a first face 3 surface of theflange portion 6.

The first rim height 7H can be substantially equal to or less than thesecond rim height 8H. Expressed in an alternative manner, the second rimheight 8H can be substantially equal to or greater than the first rimheight 7H.

Depending on the situational use, the first rim height 7H may be of aheight that is less than the second rim height 8H.

In one example, the height 7H of the first rim 7 may be about 1 mm, asmeasured from the first face 3 of the body 1 to the most distal tip orend of the first rim 7. In various other embodiments, a height of thefirst rim may be about 1 mm, or about 2 mm, or about 3 mm, or about 4mm, or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about9 mm, or about 10 mm, or may be less than about 10 mm, or less thanabout 8 mm, or less than about 6 mm, or less than about 4 mm, or lessthan about 2 mm, as measured from said first face of said body.

In another example, the height 8H of the second rim 8 may be about 2 mm,as measured from the first face 3 of the body 1 to the most distal tipor end of the second rim 7. In various other embodiments, a height ofthe second rim may be about 2 mm, or about 3 mm, or about 4 mm, or about5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9 mm, orabout 10 mm, or about 11 mm, or about 12 mm, or may be less than about12 mm, or less than about 10 mm, or less than about 8 mm, or less thanabout 6 mm, or less than about 4 mm, or less than about 2 mm, asmeasured from said first face of said body.

The channel region 9 has a floor or base which defines a channel regiondepth 9H. The floor or base of the channel region 9 is of a level, orprovides for a floor or base sections of a level, which may be one ormore of:

a level that is substantially equal to the level of the first surface 3or of the flange portion 6,

a level that is substantially lower than the level of the first surface3 or of said flange portion 6,

a level substantially higher than the level of the first surface 3 or ofthe flange portion 6.

The channel may be configured to be provided with a continuous floor orbase, or the floor or base may be of a discontinuous form (i.e. thefloor or base may comprise of apertures).

The depth of the channel region is advantageously sufficient so as toallow for a depth or thickness of material to be applied and to in-fillthe channel region 9.

The channel may be of a width that is greater than about 1 mm, orgreater than about 2 mm, or greater than about 3 mm, or greater thanabout 4 mm, or greater than about 5 mm, or greater than about 10 mm, orgreater than about 15 mm, or may be about 2 mm, or may be about 3 mm, ormay be about 4 mm, or may be about 5 mm, or may be about 6 mm, or may beabout 8 mm, or may be about 10 mm, or may be less than 10 mm.

The depth and/or width of the channel region 9 can provide for a regionof increased material, and accordingly can provide for a stronger bondor stronger plaster edge or edge of material which is joining the insertcomponent 1 to the surrounding panel material.

The channel region 9 is of a pre-determined width. This width can bedefined between the facing side walls of each of the first rim 7 and thesecond rim 8.

The width of the channel region is sufficient so as to accommodate orreceive a (curable) material.

The material may be a filler material, such as, but not limited to, oneor more of: a plaster-type or render-type material, such as a materialcomprising of gypsum, lime or cement material, or is a material capableof being decorated or may be a material which can be finished, e.g. canbe sanded to a finished surface, for a subsequent application of adecorative material, such as paint.

The insert component 1 can optionally also comprises of a ledge 10.

A ledge 10 can be provided for one or more, or each of, the at least oneopening(s) 5 of in the body 2.

The ledge 10 can provide a support surface 11 that extends substantiallyinwardly toward a centre of the opening 5 to which the ledge 10 isprovided. That is, one or more, or all, of the openings through the body2 can be provided with a ledge 10, each such ledge providing its ownsupport surface 11.

The support surface 11 allows for the seating or receipt thereon of afixture or fitting or another item or device which is to be receivedwithin the opening 5. The ledge 10 with its support surface 11 providesa structure upon which the fixture or fitting or item or device can bereceived or seated thereon.

The support surface 11 can be a surface of the ledge which faces insubstantially the same direction as the first face 3 of the body 2. Itwill be appreciated that the support surface of the ledge may be anothersurface of the ledge 10, and is not limited necessarily to being thesurface identified as item 11. For example, a rear side surface labelledas item 12 may be used as the support surface, but in that case such asurface 12 would face in a different direction.

The support surface (whether as a surface 11 or 12) can be asubstantially planar or flat surface, although it will be appreciatedthat other formations (not shown) may be provided upon the surface (11or 12) to facilitate a suitable seating of a fixture or fitting or itemor device.

The support surface advantageously provides a surface or a platform uponwhich an item is received thereon or is seatable.

The fixture or fitting may be a light fixture or a light fitting, or maybe a smoke alarm or smoke detector or other fittings or fixtures ordevices.

The second face 4 of the body 2 can comprises one or more projections13.

The projections 13 provided on the second face 4 of the body 2 canextend a pre-determined height or distance away from the second face 4.

The projections 13, in-use, allowing for a spacing of the second face 4and therefore the body 2, away from a surface (e.g. a surface of apanel) upon which the second face is to be located. That is, theprojections 13 provide or facilitate a gap or a space to be formedbetween the second face 4 and the surface upon which the body is to belocated (e.g. panel surface onto which the insert component is to bepositioned or located).

It is the space or gap formed by the projections 13 which mean a void iscreated between the body 2 and the surface to which the insert componentis to be affixed into which a (optionally curable) material can bein-filled.

The one or more projections 13 can be distributed about the second face4. The distribution may be in a manner so as to substantially evenlysupport or space the second face of the body 2 from the surface uponwhich the insert component is to be affixed. In various embodiments, theprojections 13 may be distributed substantially evenly or equidistantlyfrom each other and about the second face 4.

In one particular embodiment there may be six projections provided uponthe second face of the body 2, although it will be appreciated that anynumber of projections may be provided.

The projections upon the second face may be of a pre-determined heightor extend a distance away from the second face of about 0.5 mm, or about1 mm, or may be less than about 5 mm, or less than about 4 mm, or lessthan about 3 mm, or less than about 2 mm, or less than about 1 mm, orless than about 0.5 mm.

The flange portion 6 can extend substantially about a part, or parts, orsubstantially an entirety, of the perimeter, such as the outerperimeter, of the body 2.

The flange portion may be of any size, shape or dimension suitable forproviding a region which extends the surface area for affixation of theinsert component 1 to a surface.

Particularly where a curable medium or material (e.g. plaster) is usedfor affixation of the insert component 1 to a surface, an increase insurface area of the insert component may be advantageous for increasingor improving the surface area for a mechanical adhesion.

The flange portion 6 can be provided as two opposing sides of said body(i.e. there are cut-off or straight side portions).

The flange portion 6 can have one or more apertures 14, the apertures 14extending through the body 2. The apertures 14 can provide for voidsthrough the body 2.

The apertures 14 can be distributed about the flange portion.

The apertures 14 can be a series of similar sizes and shapes, or may bethe same or may be differently sized and shaped.

The apertures 14 allow for a curable material or medium, when applied tothe first face 3, to be pushed through the apertures 14 so as to filland be provided in contact with a surface of a panel to which the insertcomponent is being affixed.

Where for example the projections 13 are provided, then the apertures 14also allow for the material or medium to be applied and be appliedthrough to fill in the space or gap or void created by the projections13 standing the second face 4 off of the surface of a panel. This allowsfor greater amounts of material or medium to be applied and to beprovided for improved mechanical adhesion or connection between thesurface and the insert component.

Optionally, a sufficient amount or quantity of material or medium can beapplied so as to encapsulate the insert component 1 and to retain theinsert component in-situ.

The second face 4 of the body 2 may be provided as a substantiallyplanar surface, apart from the optional one or more projections 13 whichwould otherwise be provided thereon.

However, other formations (not shown) may be provided on the second face4 to facilitate further stand-off of the body from a surface to whichthe insert component is to be affixed, or may comprise of yet otherfunctional formations which facilitate improve or greater mechanicalconnection of the insert component 1 to a surface of a panel.

It will be appreciated that the insert component 1 may be of any shapeor dimension, but particularly preferably may be shapes which aresubstantially circular, oval or of a rectilinear perimeter shape.

It will be appreciated that the opening 5 may be of any shape ordimension, but particularly preferably may be shapes which may besubstantially circular, oval or of a rectilinear perimeter shape.

It will be appreciated that the ledge 10 may be of any shape ordimension, but particularly preferably may be shapes which aresubstantially circular, oval or of a rectilinear perimeter shape, or aresuitable shaped and dimensioned relative to the shape and dimension ofan associated opening 5.

A diameter of an inner perimeter of said second rim may be about 25 mmto about 104 mm, or may be about 76 mm, or may be about 86 mm, or about102 mm, or about 103 mm, or about 104 mm, or about 105 mm, or about 106mm, or may be about 160 mm, or may be about 200 mm, or may be greaterthan about 10 mm, or greater than about 20 mm, or greater than about 25mm, or greater than about 30 mm, or greater than about 35 mm, or greaterthan about 40mm, or greater than about 50 mm, or greater than about 85mm, or greater than about 100 mm, or greater than about 105 mm, orgreater than about 125 mm, or greater than about 150 mm, or greater thanabout 175 mm, or greater than about 200 mm, or greater than about 300mm, or greater than about 400 mm. The diameter may be of any diameter,but the above diameters may have particular application utility.

The flange portion 6 can be provided as a component which is detachableor attachable or that is integral with the body 2.

The first rim 7 or the second rim 8, or both first and second rims, canbe provided as a component or as each separate components, which areseparately or in a combined manner, detachable or attachable or with thebody 2.

The ledge 10 can be provided as a component that is detachable orattachable or that is integral with the body 2.

The projections 13 can be provided as separate components, or a combinedcomponent, for provision upon the second face 4 of the body 2, that isdetachable or attachable or that is integral with the body 2.

As for example shown in FIG. 8, a separate component piece 15 can beprovided. Such a component piece 15 may for example be in the form of aplate-type component piece. Such a separate component piece 15 may beprovided for seating upon the ledge 10.

The separate component 15 piece may comprise one or more apertures 16,which are configured to allow for the ingress of a material or medium asdescribed elsewhere herein.

The separate component piece 15 can be provided as a plug or cap for theinsert component 1. In this way, the insert component 1 can be put intoposition with respect to a panel P, and then the component piece 15 canbe separately installed upon the insert component 1. It will beappreciated that the component piece 15 may be provided with additionalformations to facilitate an improved quality of connection with theinsert component or with a material or medium which is to be appliedthereon.

In one embodiment, the separate component piece 15 is substantiallyplanar and of a substantially constant thickness. The thickness of theseparate component piece may be sufficient so as to align or besubstantially matched with the second rim.

In a particular example, the second rim may be of about a 2 mm height,the first rim may be of about a 1 mm height. Optionally, where acomponent piece 15 is also used, then the separate component piece maybe of about a 2 mm thickness.

FIG. 9 illustrates the assembly or relative positioning of the componentpiece 15 upon the ledge of the insert component 1.

As for example shown in FIG. 7, an insert component 1 can be positionedinto a rebated region R of a panel P. The insert component 1 can then bemechanically affixed in place, for example by application of one or morelayers of material or medium M.

According to the above description, there is provided herein for aninsert component 1. The insert component 1 has desirable utility inproviding for a structure to assist with the support of a fixture orfitting or other item or device which is to be provided in a panel (suchas a ceiling or wall).

In one preferred mode of installation, the insert component 1 is to bepositioned within a rebated region of a panel surface. The rebate beingof sufficient depth to accommodate the insert component 1. The rebatecan be of a depth such that the tip or distal end of the second rim 8 issubstantially in-line with the surface of the panel into which theinsert component 1 is to be received. That is, a rebate can be formed ina face of a panel, with the rebate being of a depth to receive saidinsert, such that an end or tip or distal point of the second rim issubstantially level or aligned with the face of the panel, or anintended level of a finished or decorated surface of the panel.

It is further contemplated that where a light fitting or fixture isdescribed, said light fitting may be substituted with any other fittingor component to be installed into a panel, such as, speakers, furniture,ducts, piping, components of alarm or safety systems (e.g., smokedetectors, gas detectors, infrared motion detectors) or any otheroutlet, utility or appliance.

It is further contemplated that any such fittings or components orsystems to be installed may be retrofitted with suitable adaptors forinstalling into a body or assembly as described in any one of thepreceding aspects or embodiments.

It is further contemplated that an assembly may comprise the body asdescribed herein, and in particular with reference to any one or more ofthe preceding aspects or embodiments.

The invention described herein provides for at least two separate rims,being of the same or different height projections of the first face ofthe body, where at least the first rim provides for a first referenceheight and the second rim provides for a second reference height. Thereference heights being made with reference to the first face of thebody or with reference to a face of a panel into which the insert is tobe affixed or received.

In certain embodiments, the first rim is of a lower or smaller height orsize then the second rim. In this manner, where for example a (curable)material such as a plaster is to be applied over the insert (for exampleto affixed of mechanically engage the insert with the panel to which itis to be affixed), a first application of a material can be made uponthe insert, and an amount of material can be applied such that thematerial is applied to a thickness to align with the first rim. A secondor subsequent layer of material may then be applied or coated, and thismay be to a thickness to align with the second rim.

The insert component 1 can be formed in any manner. However preferredmay be casting or moulding, such as injection moulding or extrusionmoulding, depending on the shape of the body 2 and the other featureswhich may be provided.

Various individual or combinations or compound materials may be used toform the insert component 1. The material to use will depend on thespecific application or use.

Examples of materials comprise one or more of: polymers such as PE, PP,PET, metals such as stainless steel, aluminium, and fibrous plasterssuch as compositions comprising gypsum, polymers, metals, compositionscomprising fibrous reinforcement, including cementitious fibrereinforced materials, fibre-glass materials.

It will also be appreciated sections or parts or portions of the insertcomponent 1 may be formed of a combination or materials.

Yet further, it may be desirable for the insert component 1 to achievecertain desired characteristics in terms of structural strength, fire orchemical resistance or ability to retard fire. For example, componentsor compounds may be included in the body or the body so formed toachieve: electrical conductivity, anti-static properties, electricallyinsulation, fire resistance or fire retarding capabilities, or even fireself-extinguishing properties.

Where reference in this specification is made to a “panel”, such a panelmay include building panels, such as ceiling panels or wall panels. Incertain typical applications, panel may be a building panel of fibrousplaster comprising gypsum.

As described above, material or medium or adhesive or other bonding orcurable agents may be utilised to assist or provide for affixation orconnection or engagement or inter-connection the insert component 1 andsurfaces of the panel. In these situations, an adhesive may bepre-applied or provided upon the insert component 1 (such as upon thesecond face 4). The adhesive or bonding agent may have a removalbacking, such as a paper or sheet, which once removed exposes theadhesive or bonding agent for use.

In various embodiments, the adhesive or bonding agent may be curable byexposure to the surface which it is desired to come into contact with.Alternatively, another means may be used to facilitate curing—such asheat source, for example infra-red, or another energy source, forexample ultra-sound, to excite the adhesive and set-off the curingprocess.

The materials or mediums or other agents can be passively or activelyactivated to cure and adhere to the panel so as to secure the insertcomponent 1 in position.

A concealing step allows for application of a sufficient amount of theone or more materials as discussed above. Application of the material isperformed by a user until the first or front face is made level with theface of the panel. Decoration or finishing materials can then be finallyapplied.

Sufficient amounts of material, such as plaster or similar materials,can be applied upon the insert component 1 and the building panel, thenallowing the material, such as plaster to cure, and then polishing thematerial, such as sanding of plaster or similar material, to achieve afinished surface, optionally with a further final finishing material,such as a paint, applied.

Various tapes, such as a jointing tape, may be optionally applied aboutjoint regions between the front face and the first face of the panel,although the present invention may allow a user to wholly negate the useof such an additional joint concealing material.

FIGS. 10 to 13 illustrate an additional feature aspect for the insert,being a perimeter retention means to hold the insert in place in arebate, however, the features as described above, alone or incombination, are interchangeable and compatible with the retentionfeature.

Referring to FIG. 10 there is provided an insert component 21 to beaffixed to, for example, a panel (P, see FIG. 13). The insert component21 comprises a body 22. The body 22 includes a first face 23 and asecond face 24. The body 21 defines at least one opening 25 that extendsbetween the first face 23 and the second face 24. The at least oneopening 25 is positioned within a perimeter 26 (such as an outerperimeter) of the body 21.

In the illustrated form the perimeter is comprised of radially extendingfingers to provide a broken circumference, however, this is merely a onepossible form (e.g. implemented for material saving measures and greatersurface area in contact with a curing material/adhesive) that may be,instead, an unbroken circular perimeter as shown in FIG. 1.

As above, the opening 25 may include a rim structure, e.g. first rim 27provided upon the first face 23 and substantially about a perimeter ofeach opening 25. A second rim 28 may be provided upon the first face 23and substantially about the perimeter of each opening 25, where thefirst rim 27 is located outwardly of the second rim 28, relative to theperimeter of each opening 25. Each of the first rim 27 and the secondrim 28 are spaced from each other to define a channel region 29therebetween. However, it is noteworthy that this feature is anindependent aspect from the general concept of a perimeter retentionmeans as will be hereinafter described.

To assist a user in holding the body 22 in place when inserted into arebate, at least one perimeter retention means 30 is provided. In theillustrated form there are three such retention devices 30 spaced,preferably evenly, about the perimeter 26. In the illustrated form theretention device/means is comprised of a resilient member 31 spanningbetween radially extending fingers such that, when a mid-point isdepressed, it will flex inwardly (toward opening 25) and bounce backoutwardly (away from opening 25).

Resilient member 31 preferably includes a protrusion 32 at the mid-pointsuch that outward bias is directed through the protrusion 32 and ontoany surface with which it is contacted. In the preferred usagesituation, the surface in contact with perimeter protrusion 32 will bethe edge/side wall of a rebate into which the body is inserted. This isgenerally illustrated by FIG. 13 where a tapered/sharp edge 33 ofprotrusion 32 may bite into rebate wall R. Once held in place by theoutward bias of one or more retention devices 30 a user can applymaterial M across the exposed first face 23 which will incorporate thebody permanently into the panel/ceiling structure.

Alternative forms of biasing/resilient/retention device are possiblewithout departing from the scope of the invention. For example, anoutwardly biased member (31, 32) may be mounted from a spring-loadedstructure to generally provide the function of expanding the perimeterinto engagement with a rebate wall or a sliding (biased or otherwisemoveable radially outwardly) member (e.g. a spike) may extend intoengagement with the rebate wall R.

Any of the disclosed insert components, such as insert component 41shown in FIGS. 14 to 23, can provide for a member in the form of a body42, to which a fitting or fixture may be mounted to, or seated upon, andthereby supported. Such a member can be provided as a structural supportfor a fitting or fixture to be supported thereon or thereto.

The insert component 41 can also provide for a particular orpre-determined (i.e. a pre-formed) dimensioned or shaped opening 45.Such an opening 45 providing the aperture for receipt therein of afitting or fixture. Such a particularly dimensioned or shaped opening 45provided by the insert component may facilitate the re-sizing oralteration in shape of an existing aperture in a panel, the insertcomponent capable of receiving such a fitting of fixture. For example,the removal of traditional incandescent or halogen type light fittingsand replacement by smaller format light fittings (e.g. LED lights)creates an issue of an overly large sized hole in a panel, with asmaller format light fitting to be replaced into that large(r) hole. Asa consequence, a device which is capable of being provided in-situ intoan existing aperture, yet which provides for a smaller (new) aperture toreceive the new (smaller format) light fitting is advantageous.Similarly, in cases where retro-fitting of light is not needed, butinstead in new builds or for new apertures being cut into panels, adevice which provides for a suitable functionality to improve structuralperformance and reduce risks of break out in a friable panel (e.g. aplaster-type panel which may become compromised as to structuralintegrity about an aperture cut therein).

The insert component (as described herein) can be located or positionedinto a rebate or recessed region of a panel, such that the insertcomponent can be subsequently mechanically fixed into place, for exampleby application of one or more layers of material, such as a curablematerial like plaster or other curable medium or adhesives, or anadhesive tape, double sided tape, or by the use of fixing means orfasteners. In this manner, the insert component can be integrated orbecome more integrated into the panel. The insert component can thenprovide a particular structure for assisting with such an integrationand as a support for a fixture of fitting.

For example, a contact or pressure sensitive adhesive may be provided ona second face of the insert (being the face which is to be put intocontact with the panel), and may be revealed upon removal of a releaseor peel sheet. Alternatively, an adhesive may be provided which is heatcured or otherwise cures upon contact or placement when placed againstthe panel to which the insert is to be mounted or affixed.

This invention can also provide for a relatively uncomplicated systemfor reducing or altering the geometry, such as shape or size of anexisting aperture, whilst at the same time provides a platform uponwhich materials, such as concealing compositions—e.g. plaster, paint orother fillers or finishes, may be applied to conceal the joint regionbetween the insert component and the surrounding panel.

It will also be appreciated the present invention may be utilised forimproving or strengthening the aperture or opening cut or made in abuilding panel to receive a fitting, such as a light fitting (or anyother outlet or utility requiring an aperture through a building panel)or a wall socket (such as for electrical outlets or indeed any otheroutlet requiring an aperture through a building panel). For example, theexisting aperture or opening referred to here may be the aperture whichis initially cut or made in a building panel to then receive a fittingor fixture.

The insert component 41 of the invention may facilitate an improvementin the strength of the building panel around an aperture or openingthrough the panel and any finishes made about the aperture so cut ormade, and in this way can help to minimise possible “break-out” in whichthe materials used around the aperture or opening are compromised as totheir structural integrity due to forces imposed upon them, for exampleby a light fitting imparting a force on a building panel about theaperture. “Break out” may result in cracking of plaster or paint orother unsightly effects in decorative finishes around the aperture.

The insert component can facilitate the alteration in the shape or sizeof an aperture or opening through a panel, for example a building panelsuch as a ceiling or a wall.

The insert component 41 as described herein can advantageously providefor ease of installation to or on a panel. In an example, the insert 41can be temporarily held in place with an adhesive, fastener, or tape,such as a double-sided tape, a pin, screw, or nail, or a projection(such as a spiked projection) formed on a flange 47 or second face 44 ofthe insert, to mechanically engage with a panel. In such an example, acurable adhesive m, such as a plaster, can be applied to the insert 41to more permanently affix the insert, whilst the temporary attachmentmeans can hold the insert in place during said curing.

In some examples, a second face 44 of the insert may comprise twoportions 51 and 52, with one portion 51 being a stepped or raisedregion. In an example, the stepped region may comprise a sidewall 51Aarranged to align the insert 41 to an aperture in a panel, and or retainthe insert 41 in an aperture in a panel.

The insert 41 as described herein may provide for a panel surfacemounted component which can be aligned with an aperture in a panel,whether the aperture is a pre-existing aperture (i.e. for resizing of anexisting hole in a panel or other retro-fitting capabilities) or anew/fresh hole (i.e. for new builds, or new installations of fixturesinto panels). The insert may also be used to fill an existing hole (i.e.for removing a fixture from a wall, and filling the existing hole).

The insert 41 as described herein may provide for a relatively lowprofile, and may include a tapered region from an outer perimeter 46towards an inner portion, the insert being thinner in profile towards anouter perimeter 46. In such an example, a plaster applied to said insertcan taper to provide a more gradual change in surface on a panel. Thismay result in a reduced bulge appearance of the insert when installed ina panel.

The insert as described herein may be provided with a rim, such as rim48 in FIG. 15, configured to act as a wall or edge to contain or alignan adhesive material applied to the insert. Additionally, the channel 49may also provide for a means to accept adhesive applied to the insert.Alone or in combination, the rim 48 and/or channel 49 may provide for ameans of containing a curable adhesive applied to the insert, and as aguide when finishing the curable adhesive (for example, when sandingafter curing) to provide a clean or neat appearance to an edge of thecurable adhesive surrounding the aperture of the insert 41.

FIGS. 14 to 23 illustrate an example embodiment of an insert. FIGS. 14and 15 shown perspective views of a second face 44 and a first face 43of the insert 41.

The insert 41 of FIGS. 14 to 23 can be affixed to a panel, and comprisesa body 42, the body comprising a first face 43 and a second face 44. Thebody 42 defines at least one opening 45 extending between the first face43 and the second face 44, said at least one opening 45 positionedwithin a perimeter 46 of the body 42. A flange portion 47 is locatedsubstantially radially outwardly from one or each of said at least oneopening 45.

At least one rim 48 is provided upon said first face and substantiallyabout a perimeter of each said opening 45. At least one channel region49 is provided in said first face 43, and substantially about theperimeter of each said opening 45, said channel region 49 locatedoutwardly of said rim 48 relative to said perimeter of each said opening45.

In an alternative embodiment, there is provided an insert component 41to be affixed to a panel, said insert component comprising a body 42,the body 42 including a first face 43 and a second face 44, and the body42 defining at least one opening 45 extending between the first face 43and the second face 44, said at least one opening 45 positioned within aperimeter 46 of the body 42. A flange portion 47 is locatedsubstantially radially outwardly from one or each of said at least oneopening 45. At least one rim 48 is provided upon said first face 43 andsubstantially about a perimeter of each said opening 45. The flangeportion 47 has a relatively greater wall thickness in a region adjacentto or at said rim 48, and is of a relatively reduced wall thickness in aregion adjacent to or at said perimeter 46 of said body 42.

As shown in FIGS. 16 and 19, the rim 48 may be a projection extendingupwardly or in a direction away from said first face 43 and said secondface 44, such that the rim 48 may be provided as a projection upstandingfrom said first face 43.

A height of the rim 48 may be about 2 mm, or about 3 mm, or about 4 mm,or about 5 mm, or about 6 mm, or about 7 mm, or about 8 mm, or about 9mm, or about 10 mm, or about 11 mm, or about 12 mm, or may be less thanabout 12 mm, or less than about 10 mm, or less than about 8 mm, or lessthan about 6 mm, or less than about 4 mm, or less than about 2 mm, asmeasured from said first face 43 of said body 42.

As shown in FIG. 19, the channel 49 may be provided as a recess in saidfirst face 43, and may be located between the rim 48 and said flangeportion 47. The rim 48 may form a first channel wall 49A of saidchannel. A height of said first channel wall 49A may be substantiallyequal to or greater than a second channel wall 49B, and the secondchannel wall 49B may be located outwardly of said first channel wall 49Arelative to said perimeter of each said opening. The second channel wall49B may be located at an inner edge of the flange 47.

The channel region 49 may have a floor or base 49C defining a channelregion depth, said floor or base 49C being of a level, or providing forfloor or base sections of a level substantially lower than said firstface 43 of said body 42 or said flange portion 47.

A depth of the channel 49 may be about 1 mm, or about 2 mm, or about 3mm, or about 4 mm, or about 5 mm, or about 6 mm, or about 7 mm, or about8 mm, or about 9 mm, or about 10 mm, or may be less than about 10 mm, orless than about 8 mm, or less than about 6 mm, or less than about 4 mm,or less than about 2 mm, as measured from said first face 43 of saidbody 42.

The channel 49 may be of a pre-determined width, said width definedbetween said first channel wall 49A and said second channel wall 49B.

As shown in FIG. 20, the width and/or said depth of said channel 49 maybe sufficient to accommodate or receive a (curable) material M.

The width of the channel 49 may be greater than about 1 mm, or greaterthan about 2 mm, or greater than about 3 mm, or greater than about 4 mm,or greater than about 5 mm, or greater than about 10 mm, or greater thanabout 15 mm, or is about 2 mm, or is about 3 mm, or is about 4 mm, or isabout 5 mm, or is about 6 mm, or is about 8 mm, or is about 10 mm, or isless than 10 mm.

The material M may be a filler material (such as, but not limited to,one or more of: a plaster-type or render-type material, such as amaterial comprising of gypsum, lime or cement material, or is a materialcapable of being decorated or may be a material which can be finished,e.g. can be sanded to a finished surface, for a subsequent applicationof a decorative material, such as paint).

One or more of said at least one opening 45 may further comprise of aledge 50, said ledge 50 providing a support surface extendingsubstantially inwardly toward a centre of said opening 45. The supportsurface may be a surface facing the same direction as said first face 43of said body 42. The support surface may be a substantially planarsurface, or alternatively the support surface may comprise a channel orrecess. The planar surface, channel, or recess may be provided toreceive a fitting or fixture as described herein. Additionally, thechannel or recess of the support surface may be provided to reducematerial thickness during a forming process of the insert. The supportsurface of said ledge 50 may be recessed from said rim 48, or may be ofa reduced height relative to said rim 48. The support surface mayprovide a surface upon which an item is seatable, such as a lightfixture or fitting, or a smoke alarm or smoke detector, or speaker, orother fittings or fixtures or devices.

The second face 44 may comprise an inner portion 51 and an outer portion52. The outer portion 52 may substantially correspond with said flangeportion 47, and the inner portion 51 may substantially correspond withsaid channel 49 and said rim 48.

The inner portion 51 may be a raised or stepped region, raised orstepped in a direction to accommodate said channel 49.

A sidewall 51A may define a step between said outer portion 52 and saidinner portion 51, and may be provided as a guide for locating said bodyinto an aperture of a panel.

The outer portion 52 may be substantially planar, or may comprise one ormore projections, such as projections 53 in FIGS. 22 and 23, the one ormore projections being of a bevelled, tapered and/or of a spiked form.

As shown in FIG. 20, the outer portion 52 may be adhered or affixed to asurface of a panel P. In one example embodiment, the one or moreprojections 53, as shown in FIGS. 22 and 23, may extend in a directionaway from said second face 44, or in a direction toward a surface of apanel to which said insert 41 is to be affixed. The one or moreprojections 53 may provide for a mechanical engagement or attachmentwith the panel, and may be provided as an array about the second face 44of said outer portion 52. The one or more projections 53 may provide fora temporary, or initial, or additional engagement with a panel, incombination with a curable material applied to the insert to furtheradhere the insert 41 to the panel. Whilst four projections 53 have beenillustrated in FIG. 22, it will be understood that any number ofprojections may be spaced or provided in arrays on the insert 41 toprovide the described initial engagement with a panel.

As for example shown in FIG. 20, an insert component 41 can bepositioned partially into a rebated region R a panel P. The insertcomponent 41 can then be mechanically affixed in place, for example byapplication of one or more layers of material or medium M. In an exampleembodiment, a first layer of material M1 may be applied, which mayinclude using a sidewall of rim 48 as a tool guide. This layer ofmaterial may fill channel 49, which is partially recessed into therebated region R of panel P. The apertures 49D of channel 49 may allowfor excess of first material M1 to escape the channel into the spacebehind the insert, which may avoid the formation of air pockets withinthe channel. This can also provide for a greater volume of material M1to be applied and received by the insert to assist with a greater volumeof the material M1 which can ultimately be cured in place to connectwith the insert.

The first material M1 may also provide for a first layer of adhesion foradhering the flange region 47 to the panel P, which may include materialM1 passing through flange apertures 47A to adhere onto a surface ofpanel P. The first material M1 may adhere the insert 41 to the panel P,and may add strength to the panel and/or insert surrounding a fixture tobe fitted. Put another way, the first material M1 may bridge orfacilitate strengthening of the connection joint made between the insert41 and the panel P.

Desirably, providing a system for strengthening the joint made betweenthe insert and the panel may provide for a system which is capable ofreceiving larger or heavier items, yet avoiding or minimising the risksof break out. That is, the insert of the present disclosure may providefor an increased load factor capability relative to a traditionalre-sizing of a hole which does not use the insert of this invention.

A second or finishing layer of material M2 may also be applied to theinsert, which may include using the face or top of rim 48 as a toolguide. This may allow the second or finishing material M2 to be appliedsubstantially level with the face of rim 48, whilst covering flange 47and channel 49. Such a configuration may provide for a finished orfinishable (e.g. by sanding and/or painting) surface.

In one preferred mode of installation, as shown in FIG. 20, the insertcomponent 41 is to be positioned within a rebated region R of a panelsurface P. The rebate R being of sufficient depth to at least partiallyaccommodate the insert component 41, for example to accommodate thesecond portion of the second face 44. Put another way, the rebate R maybe of a depth such that the second portion of the second face 44 issubstantially within the rebate, whilst the ledge 50 is substantiallyin-line with the surface of the panel into which the insert component 41is to be received. That is, a rebate can be formed in a face of a panel,with the rebate being of a depth to partially receive said insert, suchthat the flange portion 47 rests on the surface of the panel.

The flange portion 47 may have a relatively greater wall thickness inthe region adjacent to or at said channel 49, and may be of a relativelyreduced wall thickness in a region adjacent to or at said perimeter 46of said body 42. In an example, the flange portion 47 may be of a wallthickness of about 0.5 mm in a region adjacent to or at said perimeter46 of said body 42, and the flange portion 47 may be of a wall thicknessof about 1 mm in a region adjacent to or at said channel 49. The flangeportion 47 may be substantially tapered in a reducing wall thickness,said wall thickness reducing in a direction as said flange portion 47extends substantially radially outwardly from said channel 49. It willbe understood that the abovementioned flange portion thickness isexemplary, and the invention should be considered to incorporate anysuitable flange portion thickness producing a tapered, curved, and/orangled profile.

As shown in FIG. 21, the first face 43 may comprise said rim 48 defininga first projected height H1, said flange portion 47 at or substantiallyadjacent to said channel 49 defining a second projected height H2, andsaid flange portion at or substantially adjacent to said perimeter 46defining a third projected height H3. Each of said first H1, second H2and third H3 projected heights may be in reference to the second face44, or a side of the flange portion 47 on the second face 44, which maybe substantially planar as illustrated in FIG. 21.

Put another way, the rim 48 may define a first projected height H1 ofsaid first face 43, said flange portion 47 at or substantially adjacentto said channel 49 may define a second projected height H2 of said firstface 43, and said flange portion 47 at or substantially adjacent to saidperimeter 46 may define a third projected height H3 of said first face43.

The third projected height H3 may be less than said second projectedheight H2, and the first projected height H1. Similarly, the secondprojected height H2 may be less than said first projected height H1.This may result in a configuration where the flange portion 47 may slopefrom said second projected height H2 to said third projected height H3.

The first face 43 may further comprise said support surface of saidledge 50 defining a fourth projected height (indicated as H4), and thefourth projected height may be the same, or advantageously may be lessthan said first projected height, or matches the height of the firstprojected height. In an example embodiment, the support surface of saidledge 50 may be at substantially the same height as the second face 44,or a side of the flange portion 47 on the second face 44. In such aconfiguration, when the insert is installed with the second face 44 (orthe side of the flange portion 47 on the second face 44) substantiallyparallel and abutted to the panel surface, the support surface of theledge 50 may be at substantially the same height and/or level as thesurface of the panel P. Alternatively, the support surface of the ledge50 may be positioned to as to be above or below the surface level of thepanel surface or of the second face 44, or a side of the flange portion47 on the second face 44. This may facilitate a fixture or fittinginstalled in the insert to be placed at a level corresponding with thepanel surface P, or may be recessed from the panel surface or mayproject slightly beyond the panel surface as desired by aesthetics ofinstallation.

The fourth projected height H4 may be a zero, or a positive or anegative height value with respect to the reference plane defined by thesecond face of the flange portion 47. That is, the support surface ofthe ledge 50 may be provided so as to provide for a greater height ofrecess relative to the projected height of the rim (being the firstprojected height) or may be of a smaller projected height, or may be ofthe same projected height as the first projected height H1 of the rim48.

An outer edge of said flange portion 47 may define said perimeter 46 ofsaid body 42, and the first face 43 of said outer edge may comprise achamfered edge portion as illustrated in FIG. 21.

The flange portion 47 may extend substantially radially outwardly ofsaid channel 49, and may extend substantially about a part, or parts, orsubstantially an entirety, of said perimeter 46 of said body 42. Theflange portion 47 may extend continuously radially outwardly of saidchannel 49, or alternatively the flange portion 47 may extend as twoopposing sides of said body 42 (i.e. is cut-off sides, as a radiallydiscontinuous flange portion).

The flange portion 47 may comprise one or more apertures 47A, saidapertures 47A extending through said body 42. The apertures 47A mayprovide for a void through said body 42, and may be distributed aboutsaid flange portion 47.

The channel 49 may comprise one or more channel apertures 49D, and saidapertures 49D may extend through said body 42. The channel apertures 49Dmay provide for a void through said body 42, and may be distributedabout said channel 49.

The channel 49 may comprise one or more ribs 49E, and the one or moreribs 49E may extend across said channel 49. The one or more ribs 49E maybe strengthening members, and may provide for a strengthening structurebetween a wall of said rim 48 (for example channel sidewall 49A) and awall of said flange portion 47 (for example channel sidewall 49B). Theone or more ribs 49E may extend substantially across said channel 49 orsaid floor of said channel 49, or between sidewalls 49A/B of saidchannel 49. The one or more ribs 49E may be distributed about saidchannel 49.

The one or more ribs 49E may be of a height below the first face 43, orsaid one or more ribs 49E may be provided of a height recessed from saidfirst face 43, and/or of said flange portion 47. In an example, the ribs49E are provided as recessed ribs so as to not protrude through acurable material that may be applied to insert 41.

The body 42 may be substantially circular, oval or of a rectilinearperimeter shape. Additionally, one or more of said at least oneopening(s) 45 in said body 42 may be substantially circular, oval or ofa rectilinear perimeter shape, and the ledge 50 may be substantiallycircular, oval or of a rectilinear perimeter shape.

A diameter of an inner perimeter of said rim 48 may be about 25 mm toabout 104 mm, or is about 76 mm, or about 86 mm, or about 102 mm, orabout 103 mm, or about 104 mm, or about 105 mm, or about 106 mm, or maybe about 160 mm, or may be about 200 mm, or is greater than about 10 mm,or greater than about 20 mm, or greater than about 25 mm, or greaterthan about 30 mm, or greater than about 35 mm, or greater than about 40mm, or greater than about 50 mm, or greater than about 85 mm, or greaterthan about 100 mm, or greater than about 105 mm, or greater than about125 mm, or greater than about 150 mm, or greater than about 175 mm, orgreater than about 200 mm, or greater than about 300 mm, or greater thanabout 400 mm.

The flange 47 may be detachable or attachable or integral with said body42. Additionally, the rim 48 or the channel 49, or both, may bedetachable or attachable or integral with said body 42, and the ledge 50may be detachable or attachable or integral with said body 42.

A separate component piece, such as a plate-type component piece asdescribed in relation to FIG. 9, may be provided for seating upon theledge 50. The separate component piece may be provided as a plate-typecomponent piece comprising of one or more apertures. The separatecomponent piece may be provided as a plug or cap for the insertcomponent, and may be substantially planar and of a substantiallyconstant thickness. The plate-type component piece may be provided tofill an unwanted hole in a panel, and may be arranged to receive acurable material as described herein.

As described herein, the insert 41 as defined in any of the embodimentsdisclosed herein may be affixed to a face of a panel. A rebate may beformed in said face of said panel, said rebate being of a depth toreceive said insert 41, such that an end of said rim 48 is substantiallylevel or aligned with said face of said panel, or an intended level of afinished or decorated surface of said panel.

A structure may be formed in-situ with a panel, and said insert 41 asdefined in any of the embodiments disclosed herein may be affixed to aface of the panel, and a rebate may be formed in said face of said paneland sized so as to receive the insert such that the at least a portionat the perimeter of the body 42 is configured to extend to engage a sideof the rebate and retain the insert therewithin the rebate. For example,the side wall 51A of the stepped region of the second face 44 maysubstantially engage with a side of the rebate, and the flange portion47 may substantially overlap a face of the panel.

The insert as described above in relation to FIGS. 14 to 20 may becombined with any or all additional features described above. Forexample, the insert of the invention may further include projections orbumps on the rebate-facing face of the body so as to provide a spacingfunction of the body from the rebate inner surface and allow flow ofadhesive and/or curable material such as plaster. Additionally, theinsert may comprise one or more resilient elements or members, such asresilient member 31 in FIG. 10, arranged on a perimeter 46 of the body42, and/or the sidewall 51A of the second face 44.

The foregoing description of the invention includes preferred formsthereof. Modifications may be made thereto without departing from thescope of the invention.

1. An insert component to be affixed to a panel, said insert componentcomprising: a body, the body including a first face and a second face,the body defining at least one opening extending between the first faceand the second face, said at least one opening positioned within aperimeter of the body, a flange portion located substantially radiallyoutwardly from one or each of said at least one opening, at least onerim provided upon said first face and substantially about a perimeter ofeach said opening, and at least one channel region provided in saidfirst face and substantially about the perimeter of each said opening,said channel region located outwardly of said rim relative to saidperimeter of each said opening.
 2. The insert of claim 1, wherein saidrim is a projection extending upwardly or in a direction away from saidfirst face and said second face.
 3. The insert of claim 1, wherein saidrim is provided as a projection upstanding from said first face.
 4. Theinsert of claim 1, wherein said channel is provided as a recess in saidfirst face, and wherein said channel is located between the rim and saidflange portion.
 5. (canceled)
 6. The insert of any preceding claim 1,wherein a height of a first wall of the channel is substantially equalto or greater than a second channel wall, the second channel walllocated outwardly of said first channel wall relative to said perimeterof each said opening.
 7. The insert of claim 1, wherein said channelregion has a floor or base defining a channel region depth, said flooror base being of a level, or providing for floor or base sections of alevel substantially lower than said first face of said body or saidflange portion.
 8. (canceled)
 9. (canceled)
 10. The insert of claim 1,wherein one or more of said at least one opening further comprises of aledge, said ledge providing a support surface extending substantiallyinwardly toward a centre of said opening, and wherein said supportsurface is a surface facing the same direction as said first face ofsaid body.
 11. (canceled)
 12. The insert of claim 10, wherein saidsupport surface is a substantially planar surface, or wherein saidsupport surface comprises a channel or recess.
 13. (canceled)
 14. Theinsert of claim 10, wherein said support surface of said ledge isrecessed from said rim, or is of a reduced height relative to said rim.15. (canceled)
 16. (canceled)
 17. The insert of claim 1, wherein saidsecond face comprises an inner portion and an outer portion, and whereinsaid outer portion substantially corresponds with said flange portion,and wherein said inner portion substantially corresponds with saidchannel and said rim.
 18. (canceled)
 19. The insert of claim 17, whereinsaid inner portion is a raised or stepped region, raised or stepped in adirection to accommodate said channel, and wherein a sidewall defining astep between said outer portion and said inner portion is provided as aguide for locating said body into an aperture of a panel.
 20. (canceled)21. The insert of claim 17, wherein said outer portion is substantiallyplanar, or wherein said outer portion comprises one or more projections,the one or more projections is/are of a bevelled, tapered and/or ofspiked form, wherein said one or more projections extend in a directionaway from said second face, or in a direction toward a surface of apanel to which said insert is to be affixed.
 22. The insert of claim 17,wherein said outer portion comprises of an adhesive, in use to beadhered or affixed to a surface of a panel.
 23. (canceled) 24.(canceled)
 25. The insert of claim 1, wherein said flange portion has arelatively greater wall thickness in the region adjacent to or at saidchannel, and is of a relatively reduced wall thickness in a regionadjacent to or at said perimeter of said body, and wherein said flangeportion is substantially tapered in a reducing wall thickness, said wallthickness reducing in a direction as said flange portion extendssubstantially radially outwardly from said channel.
 26. (canceled) 27.The insert of claim 1, wherein said first face comprises said rimdefining a first projected height, said flange portion at orsubstantially adjacent to said channel defining a second projectedheight, and said flange portion at or substantially adjacent to saidperimeter defining a third projected height, and wherein said thirdprojected height is less than said second projected height, and saidsecond projected height is less than said first projected height. 28-31.(canceled)
 32. The insert of claim 27, wherein said flange portionslopes from said first or second projected height to said thirdprojected height.
 33. The insert of claim 1, wherein an outer edge ofsaid flange portion defines said perimeter of said body, and wherein thefirst face of said outer edge comprises a chamfered edge portion. 34.(canceled)
 35. The insert of claim 27, wherein said first face furthercomprises said support surface of said ledge defining a fourth projectedheight, and wherein said fourth projected height is less than said firstprojected height, or matches the height of the first projected height.36. (canceled)
 37. The insert of claim 1, wherein said flange portionextends substantially radially outwardly of said channel, and whereinsaid flange portion extends substantially about a part, or parts, orsubstantially an entirety, of said perimeter of said body. 38.(canceled)
 39. The insert of claim 1, wherein said flange portionextends as two opposing sides of said body, or wherein two opposingsides of said flange portion are substantially parallel.
 40. The insertof claim 1, wherein said flange portion comprises one or more apertures,said apertures extending through said body, and wherein said aperturesare distributed about said flange portion.
 41. (canceled)
 42. The insertof claim 1, wherein said channel comprises one or more channelapertures, said apertures extending through said body, and wherein saidchannel apertures are distributed about said channel.
 43. (canceled) 44.The insert of claim 1, wherein said channel comprises one or more ribs,and wherein the one or more ribs extend across said channel. 45.(canceled)
 46. The insert of claim 1, wherein said body and one or moreof said at least one opening(s) are substantially circular, oval or of arectilinear perimeter shape.
 47. (canceled)
 48. The insert of claim 1,wherein one or more of the: said flange portion, said rim, said channel,said ledge is/are detachable or attachable or integral with said body.49-50. (cancelled).
 51. A structure formed in-situ with a panel, whereinsaid insert as defined in claim 1 is affixed to a face of the panel, andwherein a rebate is formed in said face of said panel and sized so as toreceive the insert such that the at least a portion of the body isconfigured to recess into the rebate and/or engage a side of the rebateand locate and/or retain the insert therewithin the rebate.
 52. Aninsert component to be affixed to a panel, said insert componentcomprising: a body, the body including a first face and a second face,the body defining at least one opening extending between the first faceand the second face, said at least one opening positioned within aperimeter of the body, a flange portion located substantially radiallyoutwardly from one or each of said at least one opening, at least onerim provided upon said first face and substantially about a perimeter ofeach said opening, and wherein said flange portion has a relativelygreater wall thickness in a region adjacent to or at said rim, and is ofa relatively reduced wall thickness in a region adjacent to or at saidperimeter of said body.